Numerical and experimental analysis on the influence of surface layer on the resistance spot welding process for the aluminum alloys 5182 and 6016

Heilmann, Stefan; Köberlin, David; Merx, Marcel; Müller, Jens; Zschetzsche, Jörg; Ihlenfeldt, Steffen; Füssel, Uwe

doi:10.1007/s40194-019-00743-y

Cited by 4 publications

(10 citation statements)

References 9 publications

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“…The curves show that for both motions the resistance drop occurs directly at the beginning of the motion. These results correlate with the results on translation shown in [10]. Crinon and Evans [8] also demonstrated this behaviour for rotation about the electrode axis.…”

Section: The Influence Of the Contact Resistancesupporting

confidence: 86%

“…1. A detailed description of the test rig can be found in [10]. The voltage between the electrodes is measured during the movement.…”

Section: Methodsmentioning

confidence: 99%

“…The influence of translation was investigated by three different sheet movements. In [10] it was shown that for small forces a long distance has a negative influence on the electrodes. For this reason, shorter distances were investigated at higher forces.…”

Section: Methodsmentioning

confidence: 99%

“…Thus, always the same area of the electrode is stressed. A primarily furrow with possible adhesion as shown in [10] in the case of sliding friction, especially with aluminium alloys. The high plasticity as well as the low modulus of elasticity of sheet and electrode favours this adhesion [14].…”

Section: The Tribological Systemmentioning

confidence: 99%

“…Suitable parameters for a translational as well as rotational movement around y-direction are shown and the cause of its effect is explained in more detail. The selection of the parameters used for the translational motion is based on the results of a previous publication [10]. In this publication an analogy experiment for the translation was performed.…”

Section: Introductionmentioning

confidence: 99%

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Electrode wear investigation of aluminium spot welding by motion overlay

Heilmann

Baumgarten

Koal

et al. 2022

Int J Adv Manuf Technol

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The amount of aluminium sheets in future body-in-white concepts is still on the rise. There is a need for optimizing the joining techniques, caused by the different characteristics compared to the established steel components. Especially the electrode life for resistance spot welding as a reliable and established process needs to be improved. One reason for the short electrode life when welding aluminium is the insulating effect of the aluminium oxide layer. One possibility to reduce the electrode wear is the mechanical destruction of the oxide layer before the welding. This paper describes the influence of a translational and rotational electrode movement on the electrode wear. The oxide layer destruction is detected by resistance measurement. It could be shown that the destruction of the oxide layer already occurs at low movements. However, a homogeneous, large-area destruction is necessary for a wear reduction.

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Section: The Influence Of the Contact Resistancesupporting

confidence: 86%

“…1. A detailed description of the test rig can be found in [10]. The voltage between the electrodes is measured during the movement.…”

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: The Tribological Systemmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Electrode wear investigation of aluminium spot welding by motion overlay

Heilmann

Baumgarten

Koal

et al. 2022

Int J Adv Manuf Technol

Self Cite

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show abstract

Resistance Spot-Welded Dissimilar Sheets—Parametric Behavioral Analysis using Experimentation and Simulation

Pramod

Kumar²,

Kannan

et al. 2022

Trans Indian Inst Met

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Increase of electrode life in resistance spot welding of aluminum alloys by the combination of surface patterning and thin-film diffusion barriers

Brechelt,

Wiche,

Junge

et al. 2023

Weld World

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When resistance spot welding aluminum alloys, high electrode forces are required to reduce the electrical contact resistances between the electrodes and the sheet metals. The high contact resistances and the resulting thermal load cause extensive degradation of the electrode working faces. Weld spatter occurs after only a few weld cycles, significantly reducing the quality of the weld. Conventional resistance welding machines are limited in terms of maximum electrode force and weld current. As a result, weld quality and electrode life are inadequate. The aim is to increase the achievable electrode life by surface patterning the electrode working faces and creating thin-film diffusion barriers by physical vapor deposition (PVD). Patterning is intended to penetrate the oxide layers of the aluminum sheets and increase the proportion of electrically conductive contact areas. The different influences of patterning by particle blasting and contour turning will be investigated. As a further approach, thin-film diffusion barriers of up to 3 μm are deposited on the electrodes to prevent direct Al-Cu contact. Therefore, metallic coating materials (Ni and W) and an electrically highly conductive ceramic coating material (TiB2) are investigated. The combination of electrode patterning and thin-film diffusion barriers is tested in electrode life studies. It is shown that these modified electrode working faces can limit degradation effects and contribute to an increase in electrode life. In addition, the weld quality can be improved compared to the reference condition.

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Numerical and experimental analysis on the influence of surface layer on the resistance spot welding process for the aluminum alloys 5182 and 6016

Cited by 4 publications

References 9 publications

Electrode wear investigation of aluminium spot welding by motion overlay

Electrode wear investigation of aluminium spot welding by motion overlay

Resistance Spot-Welded Dissimilar Sheets—Parametric Behavioral Analysis using Experimentation and Simulation

Increase of electrode life in resistance spot welding of aluminum alloys by the combination of surface patterning and thin-film diffusion barriers

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